John Deere 325 328 Skid Steer Loader Operation and Test Service Manual TM2191 PDF - MJODTM2191.zip
A full Operation and Test guide, complete with Electrical Wiring Diagrams, covering John Deere 325 and 328 Skid Steer Loaders — packed with everything needed to maintain, troubleshoot, and repair these machines the way a professional technician would.
The Operation and Test service guide for the John Deere 325 and 328 Skid Steer Loaders contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on Operation and Test procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM2191 - John Deere 325 and 328 Skid Steer Loader Technical Manual - Operation and Test.PDF
Total Pages: 1,213 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Diagnostic Trouble Codes (DTCs)
Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes
Hydraulic Control Unit (HCU) Diagnostic Trouble Codes
Left Joystick Controller (JSL)
Right Joystick Controller (JSR)
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory Of Operation
Diagnose Observable Machine Symptoms
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory Of Operation
Diagnostic Information
Tests
Hydraulic System
Theory Of Operation
Diagnostic Information
Tests
Hydrostatic System
Theory Of Operation
Diagnostic Information
Tests
Heating and Air Conditioning
Theory Of Operation
Diagnostic Information
Tests
Dealer Fabricated Tools
tm2191 - 325 and 328 Skid Steer Loader
Table of Contents
Foreword
Technical Information Feedback Form
Section 9000: General Information
Group 01: Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating or Traveling On Public Roads
Add and Operate Attachments Safely
Park And Prepare For Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Section 9001: Diagnostic Trouble Codes (DTCs)
Group 10: Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes
Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes—Standard Controls
F9D0 - Coolant Temperature Sensor Input at 0 Volts
F9D5 - Coolant Temperature Sensor Input at 5 Volts
F965 - Fuel Level Sensor Input at 5 Volts
F974 - Alternator Voltage Out of Range High
F980 - Hydraulic Oil Temperature Sensor Input at 0 Volts
F985 - Hydraulic Oil Temperature Sensor Input at 5 Volts
F9P8 - Park Brake Output Open or Shorted to Power
F9P9 - Park Brake Output Shorted to Ground
F9H8 - Hydraulic Output Open or Hydraulic Output Shorted to Power
F9H9 - Hydraulic Output Shorted to Ground
F9J8 - Glow Plug Relay Output Open or Shorted to Power
F9J9 - Glow Plug Relay Output Shorted to Ground
F9K8 - Auto Shutdown Relay Output Open or Shorted to Power
F9K9 - Auto Shutdown Relay Output Shorted to Ground
F9M9 - Engagement and Monitor Unit (EMU) Warning Alarm Output Shorted to Ground
Engagement and Monitor Unit (EMU) Diagnostic Trouble Codes—EH Controls
000070.02 - Park Brake Release Input Erratic or Bad Data
000070.04 - Park Brake Release Input Out of Range Low
000096.03 - Fuel Level Sensor Out of Range High
000096.04 - Fuel Level Sensor Out of Range Low
000100.01 - Engine Oil Pressure Data Below Normal
000100.03 - Engine Oil Pressure Out of Range High
000107.00 - Engine Air Filter Switch Data Above Normal
000107.03 - Engine Air Filter Switch Out of Range High
000110.00 - Engine Coolant Temperature Data Above Normal
000110.03 - Engine Coolant Temperature Out of Range High
000110.04 - Engine Coolant Temperature Out of Range Low
000158.00 - System Voltage Data Above Normal
000158.01 - System Voltage Data Below Normal
000162.04 - 2-Speed Switch Input Out of Range Low
000676.05 - Glow Plug Relay Output Out of Range Low
000676.06 - Glow Plug Relay Output Out of Range High
000920.05 - Alarm Output Out of Range Low
000920.06 - Alarm Output Out of Range High
001347.05 - Fuel Valve Relay Output Out of Range Low
001347.06 - Fuel Valve Relay Output Out of Range High
001504.04 - Seat Switch Input Out of Range Low
001508.00 - Hydraulic Oil Temperature Data Above Normal
001508.03 - Hydraulic Oil Temperature Out of Range High
001508.04 - Hydraulic Oil Temperature Out of Range Low
001550.05 - AC Compressor Clutch Output Out of Range Low
001550.06 - AC Compressor Clutch Output Out of Range High
001713.00 - Hydraulic Filter Restriction Switch Data Above Normal
001713.03 - Hydraulic Oil Filter Out of Range High
001856.04 - Seat Belt Switch Input Out of Range Low
002228.09 - No HCU Data on CAN Bus Abnormal Data Range
003413.04 - Door Switch Input Out of Range Low
003597.03 - 5 Volt Sensor Supply 1 Out of Range High
003597.04 - 5 Volt Sensor Supply 1 Out of Range Low
520194.13 - Machine Model ID Wrong or Missing Calibrate Error
520850.04 - Over Ride Switch Input Out of Range Low
521050.04 - Aux Flow On-Off Switch Input Out of Range Low
522379.05 - Park Brake Release Output Out of Range Low
522379.06 - Park Brake Release Output Out of Range High
522398.02 - Park Brake Run Switch Input Erratic or Bad Data
522398.04 - Park Brake Run Switch Input Out of Range Low
523217.06 - Hydraulic Valve Power 3 to HCU Out of Range High
523218.06 - Propel Valve Power 2 to HCU Out of Range High
523219.06 - Hydraulic Valve Power 1 to HCU Out of Range High
523693.03 - Aux Hyd Channel 1 Input Out of Range High
523693.04 - Aux Hyd Channel 1 Input Out of Range Low
523694.03 - Aux Hyd Channel 2 Input Out of Range High
523694.04 - Aux Hyd Channel 2 Input Out of Range Low
523694.12 - Aux Hyd Channel 2 Input Device Fault
523917.05 - Two Speed Output Out of Range Low
523917.06 - Two Speed Output Out of Range High
523935.05 - Aux Hyd Extend Output Out of Range Low
523935.06 - Aux Hyd Extend Output Out of Range High
523941.05 - Aux Hyd Retract Output Out of Range Low
523941.06 - Aux Hyd Retract Output Out of Range High
524225.04 - Remote Start Input Out of Range Low
524264.11 - Checksum Error Unknown Fault
Group 20: Hydraulic Control Unit (HCU) Diagnostic Trouble Codes
Hydraulic Control Unit (HCU) Diagnostic Trouble Codes
000091.03 - Throttle Sensor Out of Range High
000091.04 - Throttle Sensor Out of Range Low
000091.16 - Throttle Sensor Moderately High Value
000091.18 - Throttle Sensor Moderately Low Value
000168.03 - Unswitched Power Input Out of Range High
000168.04 - Unswitched Power Input Out of Range Low
000190.12 - Engine Speed Sensor Device Fault
000237.02 - Vehicle Identification Erratic or Bad Data
001594.00 - Left Speed Sensor Input Data Above Normal
001594.01 - Left Speed Sensor Input Data Below Normal
001594.02 - Left Speed Sensor Input Erratic or Bad Data
001594.14 - Left Speed Sensor Input
001595.00 - Right Speed Sensor Input Data Above Normal
001595.01 - Right Speed Sensor Input Data Below Normal
001595.14 - Right Speed Sensor Input
002201.09 - Right Joystick CAN Data Abnormal Data Rate
002213.09 - Left Joystick CAN Data Abnormal Data Rate
002392.05 - Backup Alarm Output Out of Range Low
002660.07 - Right Joystick X-axis Mechanical Fault
002661.07 - Right Joystick Y-axis Mechanical Fault
002697.07 - Left Joystick Mechanical Fault
002698.07 - Left Joystick Mechanical Fault
003597.03 - 5 Volt Sensor Supply 1 Out of Range High
003597.04 - 5 Volt Sensor Supply 1 Out of Range Low
003597.03 - 5 Volt Sensor Supply 2 Out of Range High
003597.04 - 5 Volt Sensor Supply 2 Out of Range Low
520652.05 - Bucket Curl Solenoid Current Out of Range Low
520652.06 - Bucket Curl Solenoid Current Out of Range High
520652.16 - Bucket Curl Solenoid Current Moderately High Value
520653.05 - Bucket Dump Solenoid Current Out of Range Low
520653.06 - Bucket Dump Solenoid Current Out of Range High
520653.16 - Bucket Dump Solenoid Current Moderately High Value
520849.04 - Float Switch Input Out of Range Low
522447.05 - Right Pump Fwd Sol Current Out of Range Low
522447.06 - Right Pump Fwd Sol Current Out of Range High
522447.16 - Right Pump Fwd Sol Current Moderately High Value
522448.05 - Right Pump Rev Sol Current Out of Range Low
522448.06 - Right Pump Rev Sol Current Out of Range High
522448.16 - Right Pump Rev Sol Current Moderately High Value
522449.05 - Left Pump Rev Sol Current Out of Range Low
522449.06 - Left Pump Rev Sol Current Out of Range High
522449.16 - Left Pump Rev Sol Current Moderately High Value
522450.05 - Left Pump Fwd Sol Current Out of Range Low
522450.06 - Left Pump Fwd Sol Current Out of Range High
522450.16 - Left Pump Fwd Sol Current Moderately High Value
523217.03 - Hydraulic Valve Power 3 to HCU Out of Range High
523217.04 - Hydraulic Valve Power 3 to HCU Out of Range Low
523218.03 - Propel Valve Power 2 to HCU Out of Range High
523218.04 - Propel Valve Power 2 to HCU Out of Range Low
523219.03 - Hydraulic Valve Power 1 to HCU Out of Range High
523219.04 - Hydraulic Valve Power 1 to HCU Out of Range Low
523411.05 - Boom Down Solenoid Current Out of Range Low
523411.06 - Boom Down Solenoid Current Out of Range High
523411.16 - Boom Down Solenoid Current Moderately High Value
523414.05 - Boom Up Solenoid Current Out of Range Low
523414.06 - Boom Up Solenoid Current Out of Range High
523414.16 - Boom Up Solenoid Current Moderately High Value
523426.05 - Hyd Port Lock Solenoid Current Out of Range Low
523426.06 - Hyd Port Lock Solenoid Current Out of Range High
524264.11 - Checksum Error Unknown Fault
Group 30: Left Joystick Controller (JSL)
Left Joystick Controller (JSL) Diagnostic Trouble Codes
002697.03 - Left Joystick X-axis Out of Range High
002697.04 - Left Joystick X-axis Out of Range Low
002697.13 - Left Joystick X-axis Calibration Error
002697.14 - Left Joystick X-axis Sensor Redundancy Error
002698.03 - Left Joystick Y-axis Out of Range High
002698.04 - Left Joystick Y-axis Out of Range Low
002698.13 - Left Joystick Y-axis Calibration Error
002698.14 - Left Joystick Y-axis Sensor Redundancy Error
Group 40: Right Joystick Controller (JSR)
Right Joystick Controller (JSR) Diagnostic Trouble Codes
002660.03 - Right Joystick X-axis Out of Range High
002660.04 - Right Joystick X-axis Out of Range Low
002660.13 - Right Joystick X-axis Calibration Error
002660.14 - Right Joystick X-axis Redundancy Error
002661.03 - Right Joystick Y-axis Out of Range High
002661.04 - Right Joystick Y-axis Out of Range Low
002661.13 - Right Joystick Y-axis Calibration Error
002661.14 - Right Joystick Y-axis Sensor Redundancy Error
Section 9005: Operational Checkout Procedure
Group 10: Operational Checkout Procedure
Operational Checkout
Section 9010: Engine
Group 05: Theory Of Operation
POWERTECH POWERTECH is a trademark of Deere & Company 2.4 L & 3.0 L (4024 & 5030) John Deere Engines
Group 15: Diagnose Observable Machine Symptoms
2.4 L & 3.0 L Diesel Engine for 325 & 328 Skid Steer Loader
Engine Fuel System Component Location
Group 25: Tests
Engine Speed Test and Adjustment
Engine Power Test Using Turbocharger Boost Pressure
Section 9015: Electrical System
Group 05: System Information
Electrical Diagram Information
Electrical Schematic Symbols
Group 10: System Diagrams
Fuse Specifications
System Functional Schematic, Wiring Diagram, and Component Location Master Legend
System Functional Schematic and Section Legend
System Functional Schematic, Wiring Diagram, and Component Location Master Legend—EH Controls
System Functional Schematic and Section Legend—EH Controls
Engine Harness (W1) Component Location
Engine Harness (W1) Wiring Diagram
Cab Harness—Standard (W2) Component Location
Cab Harness—Standard (W2) Wiring Diagram
Front Chassis Harness—Standard (W3) Component Location
Front Chassis Harness—Standard (W3) Wiring Diagram
Backup Alarm Harness (W4) Component Location
Backup Alarm Harness (W4) Wiring Diagram
Dual Flasher Harness (W5) Component Location
Dual Flasher Harness (W5) Wiring Diagram
Horn Harness (W6) Component Location
Horn Harness (W6) Wiring Diagram
Air Conditioner and Heater Harness (W7) Component Location
Air Conditioner and Heater Harness (W7) Wiring Diagram
Wiper Harness (W8) Component Location
Wiper Harness (W8) Wiring Diagram
12 Volt Auxiliary Power Harness (W9) Component Location
12 Volt Auxiliary Power Harness (W9) Wiring Diagram
Beacon Harness (W10) Component Location
Beacon Harness (W10) Wiring Diagram
Cab Harness—Deluxe (W12) Component Location
Cab Harness—Deluxe (W12) Wiring Diagram
Front Chassis Harness—Deluxe (W13) Component Location
Front Chassis Harness—Deluxe (W13) Wiring Diagram
8-Button Controller Harness (W15) Component Location
8-Button Controller Harness (W15) Wiring Diagram
Operator Convenience Package Harnesses (W18 and W19) Component Location
Operator Convenience Package Harnesses (W18 and W19) Wiring Diagram
Electric Quik-Tatch (W28) Component Location (S.N. 131877— )
Electric Quik-Tatch (W28) Wiring Diagram (S.N. 131877— )
Helper Fan Control and Tee Harness (W29 and W30) Component Location
Helper Fan Control and Tee Harness (W29 and W30) Wiring Diagram
Engine Harness—EH Controls (W31) Component Location
Engine Harness—EH Controls (W31) Wiring Diagram